Karoo Meat of Origin standard: Abattoir

Transcription

1 Karoo Meat of Origin standard: Abattoir

2 Karoo Meat of Origin Standard: Abattoir 1. Origin of animals a. Farm declaration of origin b. Accredited producers only 2. Carcass specification 3. General a. HAS point compliance b. Certificate of Acceptability as Food Premises (R918) c. Management Responsibility 4. Animal welfare a. Unloading b. Lairage (at Abattoir) 5. Killing and slaughtering 6. Carcass chilling 7. Facilities & premises 8. Personnel hygiene and Protective clothing 9. Quality management a. ph report b. Certificate of Conformance c. Micro Records d. Calibration of equipment 10. Traceability 11. Cleaning and sanitation 12. Maintenance 13. Pest control 14. Storage 15. Transport 16. Document and record control 17. Audits 18. Non-conformance to specifications Approved by: Directors Owner: Magda Combrink Page 2 of 14

3 1. Origin of animals a. Farm declaration of compliance to KAROO MEAT OF ORIGIN standards i. Animals, ready for slaughter, may only be removed from the farm if accompanied by a DECLARATION OF COMPLIANCE TO KAROO MEAT OF ORIGIN STANDARDS (Addendum 1). ii. This form must be completed and signed by the producer (or an authorized person). iii. The producer will keep a copy of the DECLARATION OF COMPLIANCE TO KAROO MEAT OF ORIGIN STANDARDS, while the other copy will accompany the specific truck to the dedicated abattoir. The abattoir will only accept animals for slaughter that are accompanied by a Declaration of Compliance. iv. Keep this copy on file for auditing purposes. b. Accredited/ certified producers only i. Check the KMOO database to confirm that the producer/ farmer are certified and that their certification is still valid. 2. Carcass specification Lamb and mutton Breed Preferably meat breed types with good bone: muscle ratio with an even fat distribution. Carcass mass 14 to 24kg Classification Age classes A, AB, B and C Fat classes 1 to 6 Conformation 3, 4 and 5 Damage Only F1 damage allowed In particular, the following classes of carcasses do not qualify for certification: Age classes: AB, BBB, CCC stamped MD indicating rams or carcasses showing signs of late castration in those age groups Carcasses with code 2 and 3 damage Approved by: Directors Owner: Magda Combrink Page 3 of 14

4 3. General a. HAS point compliance i. A minimum of 75% average score to be obtained during HAS audit as conducted by the Department of Agriculture. ii. It will be expected of you (the abattoir) to supply the summary page of the HAS audit report to the auditor. This will be forwarded to KMOO with the KMOO audit report. b. Certificate of Acceptability as Food Premises (R918) i. There shall be a valid certificate of acceptability for the food premises, in the name of the person in charge. ii. The certificate of acceptability shall be displayed for the information of the public. c. Management Responsibility i. Management shall ensure that all relevant staff have sufficient knowledge and training in meat hygiene principles and practices ii. Management shall ensure that hygiene standards are understood and complied with by all personnel, visitors and contractors before entering the premises. iii. Management will ensure that there is a documented customer complaint system and/or procedure in place. iv. There shall be periodic review and verification of the food safety system onsite which covers the entire process. The review process shall include customer complaints, audits and corrective actions, etc. 4. Animal welfare a. Unloading i. Injury free. ii. Non slip floor. iii. Correct slope <30. iv. No delay in unloading. v. Good lighting. b. Lairage (at Abattoir) i. Clean drinking water to be available freely. ii. Shade to be provided. iii. Lairage to be cleaned between each batch. iv. Non slip floor. Approved by: Directors Owner: Magda Combrink Page 4 of 14

5 v. Not to be overcrowded : 0.56 m² per animal vi. Animals should not be transported more than 250km to an abattoir. Any distance further than 250km needs to be approved by KMOO first. vii. Animals to be rested before slaughter as follows: a. Transport distance <100km: resting period 1 hour minimum b. Transport distance 100km to 500km: resting period 2 hours minimum viii. Adequate ventilation is required. ix. Feeding of animals when required. x. Lairages equipped with notices specifying the number and type of species permitted. 5. Killing and slaughtering a. Humane procedures must be in place. b. Veterinary inspector to inspect animals before killing (Act 87 of 1967). c. Animals heavily contaminated with faeces and/ mud should be excluded. d. Congestion and excitement to be prevented from lairage to stunning area. e. Sticks should not be used on moving animals. The animals should be moving in single file. f. No animal should be left in the stunning area during breaks. g. Emergency slaughter facility and SOP in place. h. Stunning must be effective and done according to the manufacturers specifications. Recommended to be done for 3 seconds at 90 Volts (0.8 Ampere). i. The animal should be shackled, hoisted and neck slit open within 30 seconds. j. Electrical stimulation should once again be done according to the specifications of the manufacturer. Recommended to be done for seconds/ Volts/ 0, 6 Amp. It is critical that the ph of the loin muscle is lower than 6.0 about 1 hour after kill. k. A system should be in place to ensure knifes are sharp. l. A 2 knife system should be in place. No mixing of clean and dirty knifes. m. No dressing started before the completion of the bleeding. Minimum of 6 minutes for sheep. n. Inspect carcass and offal for diseases. o. SOP in place for contaminated and/or dropped carcasses. p. No signs of hair, blood, faeces, soil, etc. may be present on the carcass before cooling. q. If allowed, wash the carcass with cold water with 2ppm available chlorine. r. All sterilisers should be 82 C with proper overflow to ensure clean water. Approved by: Directors Owner: Magda Combrink Page 5 of 14

6 s. Carcass correctly tagged with Lot no/ tracking number on KMOO tag. t. Carcasses clearly and correctly marked/ stamped for KMOO. When stamp is not in use it should be cleaned and then kept in secure place on the abattoir premises. u. Only ink approved for use on foodstuffs should be used. 6. Carcass chilling a. Cold room to operate between 0 and 2 C, RH 85-90% and air speed 0.75m/sec. b. Deep leg muscle temperature to be below 10 C within 16 hours after slaughtering. Temperature to be below 5 C before carcasses can be dispatched. c. No mixing of hot and cold carcasses. d. No non-food item or product other than meat stored in carcass chillers. e. Floors to be rinsed daily. All floors, doors, walls and rails to be cleaned and sanitised after each cycle. f. Meat not to be in direct contact with floor and walls. g. Sufficient spacing to be left between carcasses for optimum air circulation. h. Cold room to be free from bad smells and odors. 7. Facilities & premises Covered in HAS audit. Refer where necessary. a. Design and facilities b. Personnel facilities, toilets and hand washing facilities c. Site and premises 8. Personnel hygiene and Protective clothing Covered in HAS audit. Refer where necessary. 9. Quality management a. ph-report (spec is less than 6) i. The ph of at least one carcass per cradle (5 or 6 per cradle) must be checked before entering the chiller. The ph should be lower than 6 about 1 hour after kill. Reject carcasses with ph>6. Record these ph's. Approved by: Directors Owner: Magda Combrink Page 6 of 14

7 ii. Keep these records on file for auditing purposes. b. Certificate of Conformance i. It is expected that each load of carcasses (per customer) must be accompanied by a Certificate of Conformance. ii. The COC can either be completed in full or the temperatures (every 5 th carcass should be measured) and ph s need to be completed with a Serial Number Tracking Invoice accompanying the COC per customer. The batch numbers need to be linked to the Certification numbers of the farmers. The abattoir must be able to proof full traceability in the process. iii. Duplicates should be kept on record for auditing purposes. iv. See Addendum 2 c. Micro records i. Counts on receiving must be as follows: Total count <50 000/g E.Coli Coliforms Staph. Aureus Salmonella Clostridium perfringens <10/g <100/g Absent/g Absent/25g Absent/g d. Calibration of equipment i. Calibration and verification of measuring equipment: 1. All scales and thermometers shall be calibrated annually and calibration certificates shall be kept on file. 2. Mass pieces used for the verification of scales shall be calibrated every two years and calibration certificates obtained. The mass pieces used for the verification of scales shall be a mass that is similar to the final mass of the product being weighed. 3. Equipment shall be labelled with the calibration details. Approved by: Directors Owner: Magda Combrink Page 7 of 14

8 4. Monthly verification of the equipment is to be done on site and records kept. ii. Scale verification: 1. Once a month the scales must be verified to ensure they are accurate. 2. Calibrated mass pieces must be put on the scale and the weight recorded. All readings must be recorded. Any readings that are more than one division out must be reported to Management. All nonconformances must be recorded on the corrective action form, and the necessary action and follow up recorded. 3. Management should get the scales to be calibrated by the company servicing the scales. The scale company is to supply a calibration certificate for each scale calibrated. iii. Thermometer verification: 1. The verification of the thermometer should be done monthly by using the ice point method. 2. Ice Point Method: Fill a glass with crushed ice. Add clean cold tap water until the glass is half full and stir well. 3. Put the probe of the thermometer into the glass. Ensure the sensing area of the thermometer is submerged in the ice water and stir the water and ice with the probe. 4. Wait at least 30 seconds or until the indicator stops moving. 5. Record the temperature on the indicator on a verification sheet. 6. If the thermometer does not read between +1 C and 1 C it must be reported to Management. All non-conformances must be recorded on a corrective action form, and the necessary action and follow up recorded. Management should send the thermometer to a SANAS accredited supplier in order to be fixed and calibrated. The company repairing the thermometer must supply a calibration certificate when returning it. iv. Fridge, freezer and truck gauges: 1. Once a month the fridge, freezer and truck gauges must be verified by placing the already verified thermometer inside the fridge, freezer or truck and leaving it there for a few minutes until the indicator stops moving. 2. The reading on the dial and the thermometer must be recorded on the verification sheet. Should the readings be more than 1 C apart it must be reported to management. All non-conformances must be recorded Approved by: Directors Owner: Magda Combrink Page 8 of 14

9 on the corrective action form, and the necessary action and follow up recorded. 3. When the gauges are not accurate, an accredited company must calibrate the gauges and supply a calibration certificate. 10. Traceability a. Only animals from Certified KMOO farmers may be used for KMOO. b. The abattoir will only accept Karoo Meat of Origin animals if a Declaration of Origin accompanies the specific truck. c. Karoo Meat of Origin animals should be kept separately in a dedicated pen. d. Tracking number: The animals should each receive a unique carcass number (tracking number), which must ensure full traceability to the live animal and the farmer. e. The identification mark must be visible at all times. f. All relevant information must be documented and recorded. g. At the point of carcass classification and weighing, a specific Karoo Meat of Origin mark must be stamped on the specific carcasses. h. All Karoo Meat of Origin carcasses must be easily identifiable in the chiller as well as in the truck delivering the carcasses. 11. Cleaning and sanitation Covered in HAS audit. Refer where necessary. 12. Maintenance a. An effective maintenance program shall be implemented to ensure the proper functioning of equipment, buildings and vehicles. b. Any equipment that is critical to food safety shall be identified and a planned maintenance program set up. The planned maintenance program shall stipulate the equipment to be maintained; work to be carried out on equipment, frequency of maintenance. c. Only food grade lubricants may be used on equipment within the butchery. Material safety data sheets (MSDS) shall be kept on file for the lubricants used on site. Approved by: Directors Owner: Magda Combrink Page 9 of 14

10 d. Whenever any maintenance is carried out in the abattoir a job card is to be completed. The equipment and area is to be properly cleaned after maintenance has been completed and this is to be signed off on the job card. e. Planned maintenance should be done as far as possible outside of production hours. SOP (to prevent contamination of product) to be in place when maintenance needs to be done in production area while production is taking place. 13. Pest control a. Effective measures shall be taken to eliminate flies, other insects, rodents or other pests in the abattoir. b. Fly electrocuters shall be of the design with the glue boards to catch the flying insects and shall be serviced at least monthly. The unit shall be positioned in the abattoir where is will not be over any meat and away from natural light. The ultraviolet tubes shall be replaced annually and it should be protected against shattering. c. The facility shall be properly proofed at the bottom of the external doors and at windows to prevent the entry of pests. d. The facility shall be kept clean to prevent the attraction of pests to the facility. 14. Storage Covered in HAS audit. Refer where necessary. 15. Transport a. Deep bone muscle temperature of carcasses transported by truck should be less than 5 C maximum and should be delivered at 5 C maximum. b. Trucks should be pre-cooled to 2 C at least before loading carcasses. c. Trucks need to be clean, free of taints or smells. d. Loading area temperature must be a maximum of 12 C when in use. e. Carcass should be transported in hanging position. Meat not to be in direct contact with the floor of the vehicle. f. Sufficient spacing to be left between carcasses for optimum air circulation. g. Personal clothing as well as protective clothing should be clean. Approved by: Directors Owner: Magda Combrink Page 10 of 14

11 16. Document and record control a. All documents and records developed for the food quality and safety program shall be written in a similar format and approved before use to ensure that the correct and most updated version is available for use. b. All documentation must be written in a standard format and must include the following: Page number Revision/ Version number Effective date Approved by and designation Documentation number c. Controlled documentation must be readily available for use by employees conducting tasks described in the applicable documents. No hand written changes are permitted. d. When documents and records need to be updated the date and the revision number is to be updated and the document then reissued. e. Documentation Distribution Register This document is to be used every time a new or revised document is issued for use. The person issued to, document title; page number, version number and date issued must be recorded. Where the documentation is replacing existing documentation the old documentation shall be recalled from the responsible person. The person receiving the documentation must sign the document. f. Amendment Register: Whenever a document is amended this document must be completed. The Doc. No., page no., version, a brief description of the amendment and effective date must be recorded. The assigned person amending the documentation must sign the document. When amending the documents the version number and effective date must be changed. g. Examples of forms that may be used are available on request from KMOO. 17. Audits In order to ensure full compliance to above-mentioned specifications, the Karoo Meat of Origin scheme will be conducting annual (unless otherwise specified) audits. This will be conducted by an independent auditing body (e.g. SAMIC), as appointed by the KDF. This audit will include a paper audit to cross check figures with farmer s capacity/ animals received by abattoir/ animals received from abattoir, etc. Approved by: Directors Owner: Magda Combrink Page 11 of 14

12 18. Non-conformance to specifications a. Carcasses which do not comply with the above-mentioned specifications will not be eligible to be used for Karoo Meat of Origin. b. The right to use the certification mark will be terminated immediately if an abattoir is found, at any stage, not to be adhering to the specifications. c. We also ask that any person who is aware of malpractices anywhere in the chain to report it to KMOO via our Website Contact Us at Approved by: Directors Owner: Magda Combrink Page 12 of 14

13 Addendum 1 DECLARATION OF COMPLIANCE TO KAROO MEAT OF ORIGIN STANDARDS Verklaring dat die eienaar van die diere gelewer (aan die slagpale) voldoen aan die Karoo Meat of Origin standaarde. Declaration that the owner of animals delivered to the abattoir complies with the Karoo Meat of Origin standards. Ek / I, (volle name) (full name) van die plaas/plase of the farm(s) (plaas se naam) (farm name/s) en gesertifiseer as n Karoo Meat of Origin verskaffer met nommer and accredited as a Karoo Meat of Origin supplier with number verklaar hiermee / hereby declare: dat die diere gelewer deur my aan that the animals delivered by me to (Slagpale Naam) (Name of Abattoir) aan al die Karoo Meat of Origin spesifikasies voldoen. comply to all the Karoo Meat of Origin specifications. Geteken / Signed: Datum/Date: Approved by: Directors Owner: Magda Combrink Page 13 of 14

14 Addendum 2 CERTIFICATE OF CONFORMANCE Date: It is hereby confirmed that this batch of meat has been inspected by the meat inspector and is fit for human consumption. It has been sourced and slaughtered in accordance to the Meat Safety Act 40/2000. All measures have been taken to ensure the meat is free of physical, chemical and microbiological contamination. All meat is Certified Karoo Meat of Origin and has been marked as such. It conforms to the agreed Karoo Meat of Origin standard. Tracking number From farmer certification no Temperature(Every 10 th carcass to be measured) ph Abattoir: Certification number Signed: Designation: Approved by: Directors Owner: Magda Combrink Page 14 of 14